Roofing shingle and method of making same



June 2, 1931. l.. KlRscl-IBRAUN ET AL. 1,807,918

ROOFING SHINGLE AND METHOD OF MAKING SAME Original Filed Aug 7, 1925 2 sheets-sheet 1 June`2, 1931. L. KIRSCHBRAUN ET Al. -1,807,918

ROOFING SHINGLE AND METHOD OF MAKING SAME Original Filed All@ 7. 1925 2 sheets-sheet 2 Patented June 2,`1931 UNITED. sTATEs PATENT oFF-ICE Y LESTER KIRSGHBRAAUN, OF LEONIA, NEW JERSEY, AND OTTO A. HEPPES, lOE 12A. GRANGE' ILLINOIS, ASSIGNORS, BY MESNE ASSIGNMENTS, TO THEYPATENT 'AND LICENSING CORPORATION, OF BOSTON, MASSACHSIETTS,l A CORPORATION OF :MIAS- SACHUSETTS nooFINe dsinn-cfu: AND mnrnonor MAKING SAME.

originaiapplication nled August 7, 1925, serial No. 48,840. Divided aim mi application mea Novmter 2o, 1928. ser1a11v0.320,682.

- This application is a division of our copending application Serial No. 48,840, filed August 7 1925, for roofing shingle and method of producing same. The invention relates to asphalt shingles adapted to be laid .with others of similar construction in overlapping courses-and serving as protecting or covering elements for the roof or side wall of a build- 10 uch shingles usually comprise a fibrous base or foundation, saturated with asphalt or equivalent waterproofing material, coated on one or both faces with an adhesive surface or bed' layer of asphalt in which is partially embedded on its outer or exposed surface a surface layer of crushed slate, stone, granite, or like'material, havingornamental, wear resistin fand reproong characteristics. ince -sucl -shingles are of thin construc- A tion, they present a monotonous or fiat apearance when-laid on a roof surface in overappir'igA courses. Moreover, because o f the inherent flexibility of such shingles, they are sometimes subject to curling, and their butt ends are liable to be raised'by the wind, and allow rain to beat in under them so that the appearancel and the waterproofing qualities of the roof covering are impaired. Hence, the primary object of the present invention, gen- A erally stated, is to Yprovide an asphalt or prepared shingle of a thickbuttjend construction, which will impart an appearance of substantial solidity or thickness to a roof or other eirposed surface when laid, and which will not be raised .by the action of the elements. A further object is to provide a method for the-production ofsuch shingles in'an economical and eicient manner. Brieiy'stated, the shingle ofthe present 40 ness construction, the butt end portion as laid being of the greatest thiclmess, -and the upper end portion of least thicknessafj'lhere may be portions intermediate the thicker and thinner portions of one or-'more intermediate thicknesses, and these portions of varied-thickness may either be sharply 'defined or stepped;

or they may merge more or less Agradually one into another. In any event, how-- ever, the lower or butt portion is of a thicker invention is of a stepped or variable thick-a.

thereof, when considered in conjunction with' construction than the upper portion of the shingle, and is provided with an adhesive bed coating comprlsing a plurality of strata of asphalt between which are sandwiched and in which are embedded a layer -or layers of crushed slate or equivalent mineral grit. The strata of asphalt and the layer or layers of grit-are firmly united or bonded to form an integral coating, and thereis a surface layer of grit partially' embedded in the asphalt stratum immediately thereunder. In a shingle where there are portions of intermediatev thickness, these portionsare provided with bed coatings comprisingfewer asphalt strata and fewer layers of grit therebetween than' the butt portion, but this bed coating is' also surfaced with a layer of grit. The upper portion of the shingle, however, isv coated with only a single stratum ofasphalt in which is partially embedded the surfacelayer of crushed slate. The entire surface of the shingle is thus formed of a partially embedded layer of -grit or crushed mineral material.

The -novel shingleamay be produced :by coating a sheet of asphalt-saturated fibrous L material, such as is usually employed in the manufacture of roofings, with a layer of asphalt, then partially embedding a layer of mineralgrit in the asphalt coating and applying a plurality of asphalt coatings along successively narrower portions or longituor zones, thenal coating of asphalt, with its Asurface layer of grit, covering the entire surface of thesheet. When such a sheet is cut transversely of its len shingles'embodying-'the present inventlon are` roduced.

The invention may best be un erstood from the following more detailed description uesl the 'accompanyingdrawings, in which,- l

Flgurel represents in sectional view, dia- 10 grammatically and conventionally, a portion of the apparatus by means of which the shingle may be produced.y

Figure 2 represents a plan View of the same.

Figure 3 illustrates a shingle embodying the present invention.

Figure 4 represents a section on the line 4.-4 of Figure 3. Y

Figure 5 represents in section a shingle constituting another embodiment of our invention.

-Figure 6 represents a strip shingle embodying the invention.

Figure 7 is a plan view of apparatus for applying to a sheet successively narrower central bands of coating and grit.

Figure 8 is a plan view of apparatus for applying to a sheet successively wider bands of coating and grit, the lina-l band extending to the edges of the sheet.

Referring to the drawings, in the diagrammatic illustration shown in Figures 1 and 2, a sheet of material S, of indeterminate length, is represented as undergoing a treat-- ment in accordance with the present invention in the course of its travel from right to left, as viewed in the drawing.' The sheet material may consist of the felt or equivalent fibrous material usually employed in the manufacture of roofing, saturated or impregnated by a previous treatment with asphalt or other suitable waterproong agent.

In the practice o-f the present invention, the sheet S, in its horizontal travel or propulsion produced by suitable means (not shown), is shown as being first Vcoated over its entire surface with asphalt in which there is partially embedded a surfacing layerA of grit. `To this end, the sheet S is subjected on its upper face to a stream of semi-fluid (preferably molten) asphalt delivered thereonto lfrom a coating nozzle 1 located. directly thereabove. The asphalt coated sheet passes from the coating nozzle over a guide roll 2, above which and acting on the coated sheet is a scraper or doctor 3 (which may, if desired, be a roll), which acts to distribute the semi-fluid asphalt evenly over the sheet and to remove any surplus asphalt from the sheet in its passage thereby.

Theasphalt-coated sheet is then surfaced with a layer of crushed slate or other equivalent grit, while the asphalt is still in its semi-plastic state. For this purpose, there is provided a hopper or grit distributor 4, suitably supplied with gritin regulated and controlled quantity from a grit feed conduit 5 thereabove, which is arranged to distribute grit evenly and uniformly throughout the width of the sheet. The'grit surfaced sheet is then passed successively through a pair of press rolls 6, 6a and under a guide roll 7 located below the lower roll 6a. The press rolls partially force or embed the slate into the asphalt and in the downward passage of the sheet from the lower press roll 6a to the guide roll 7 any non-adherent or excess and unembedded grit falls from the sheet into a trough or receptacle 8. Thus far we have described a method of coating and surfacing fibrous material, all of which is well known in the art.

According to the present invention, however, provision is made for further increasing the thickness of the sheet material in longitudinal zones thereof. This is done by applying further coatings of asphalt on Athe sheet along successively narrower portions or longitudinal zones and partially embedding grit in each asphalt coating. To this end, the grit surfaced sheet passes from the guide roll 7 over a guide roll 9, again assuming a horizontal travel, and is now subjected to another asphalt coating operation along a narrower side portion or longitudinal zone, after which slate is partially embedded in the asphalt-coated portion. For this purpose, the coated sheet passes successively under a coating nozzle 10, arranged to deliver semifluid asphalt on the desired width, thence over a guide roll 11, above which a doctor or scraper 20 of suitable form is positioned in a manner to distribute the asphalt uniformly thereon along a longitudinal zone and to remove any excess asphalt therefrom. The partially coated sheet is then subjected to a surfacing operation, by delivering grit thereonto on its freshly asphalt-coated portion from a hopper 15V. The grit is partially embedded as previously, by passage of the sheet through a second pair of press rolls 16, 16a, and provision is made to remove excess grit, as previously, by a downward passage of the sheet about the press roll 16a to a guide roll 17, the excess or unembedded grit dropping into a trough 18. The sheet now consists of thicker and thinner side portions, and

may be cut transversely of its length into rigid to resist the action of the elements and` to ifmpart a substantial appearance to the roo It may, however, be desirable to still further increase the thickness of a still narrower side portion of the sheet which is to form the butt portion of the shingles, and in such cases this butt portion of the sheet may be subjected to another thickening operation. In such cases the sheet passes from the guide rolls 17 successively under a coating nozzle 19, which is arranged to distribute asphalt over the desired width of sheet, thence by a scraper'21, and under a grit distributor 22, which is positioned to surface the last coated portion with grit. The grit is partially embedded in the asphalt coatin by a pair of press rolls 26, 26a, and the t ickened sheet ingoia side portion is desired, it may be subjected to further thickening operations.

The sheet is cut transversely of its length Ainto shingles of the desired lengthby transother suitable cutting` verse cutters ori an mechanism, the resu ting shingles presenting an appearance as illustrated by an embodiment shown in Figure 3. The shingle is of stepped or' varyin thickness, and comprises a waterproof brous base or foundation W, coated with a plurality of superposed asphalt strata a, a1, a2, each respectively Vhaving mineral grit g, g1, g2, embedded therein, said strata being progressively shorter and all extending from the'butt end of the shingle. The upper portion T thus has only one stratum a, and surfacing gfof grit, and is thinner than the lower or butt portion B, and there is an intermediate portion I having one less coating of asphalt and one lesssurfacing than the butt portion. As a matter of fact, there may be a plurality of intermediate portions, so that a very gradual stepped reduction in thickness from the butt to the upper en d of the shingle may be had. In any case, however, the butt portion is of sucient thickness to be rigid and to impart a substantial appearance to the roof.

While we have described a process in which only one surface of the shingle is subjected to a pluralityT of coating and gritting operations, it will be understood that both surfaces of the shingle may be so treated. Moreover, diiferent colored grits may heembedded in the successive coating operations, and similarly the size of the grit material and its composition or quality may be varied. For example, the lowermost gritsurfacing may be of very fine and cheap grit, whereas the uppermost or exposed surface may be coarse and more expensive grit granules. Or the upper portion of the shingle maynot be surfaced with grit, whereas the lower portion may be provided with a plurality of surfacings.

While we have described a construction in which the lower portion of the shingle is thicker than the upper or unexposed portion, thereby allowing for the saving of asphalt and grit, it is, of course, possible to provide a construction where the entire shingle is of uniform thickness and'is provided with aplurality of strata of asphalt between which are the layers of grit.

By the shingle construction described herein, we may produceJ shingles of thick construction, which are more economically manufactured than shingles which are thickened by the employment of a thick fibrous foundation, or which are mainly thickened by the use of a thick asphalt coating. That is, in the thickened shingle of. the present invention, we have substituted the use of grit as a thickening constituent, in place of asphalt or fibrousv material.` Moreover, in so doing We have been primarily concerned with the thickening of the butt or exposed portion, since it is this portion which imparts to the roof its waterproofing characteristics and its appearance.

It is evident that, with a sheet that is wider than the length' of the shingles to be cut there-- from, the narrowest zone of asphalt and grit may be located in the central portion of the sheet, as shown in Figure 7, and the sheet then slit longitudinally along its longitudinal median line to form .strips from which shingles embodying the present invention may be cut. As previously indicated, instead of first applying. layers of asphalt and grit over the entire surface of the sheet, and then applying thereon successively narrower layers of asphalt with grit therein, the operation may bereversed. That is, we'may apply the narrowest layers first, and then apply successively wider layers, until the final layer of asphalt with the grit partially embedded therein vcovers the entire vsurface of the sheet. This i-s illustrated in Figure 8. In some as pects, this is a preferable mode of operation, since a moregradual taper is produced, as the overlapping layers tend to smooth themselves at the steps, or shoulders, at the l edges of the several coatings.

this invention, it should be evident to those y skilled in the art that it is capable of various changes and modifications which lie within vits spirit and the scope of the appended claims.

We claim:

1. In the manufacture of asphalt roofing elements, a process which comprises applying a continuous layer of bituminous coating to a face ofa sheet of waterproof fibrous materia-l, said layer extending over the entire widthwise extent of said sheet, embedding grit in said coating, applying a second con,- tinuous layer of bituminous coating over said embedded grit, said second layer of coating being narrower than the width of the sheet and having the longitudinal borders thereof spaced inwardly from the marginal edges of the sheet-embedding grit in said secondlayer of coating, slitting the sheet longitudinally through said second coating layer and severing shingle elements from the sections formed by the slitting.

2. In the manufacture of asphalt roofing elements, a process which comprises applying a continuous layer of bituminous coating to a face of a sheet of waterproof librous material, said layer extending over the entire widthwise extent of said sheet, embedding grit in said coating, applying a second continuous layer of bituminous coating over said embedded grit, said second layer of coating being narrower than the width of the sheet and having the longitudinal borders thereof spaced inwardly from the marginal edges of the sheet, embedding grit in said second layer of coating, slitting the sheet longitudinally along the median line of said second coating layer and severing shingle elements from the sections formed by the slitting.

3. Inthe manufacture of 'asphalt roong elements, a process which comprises applying a continuous layer of bituminous coating to a face of a sheet of Waterproof fibrous material, said layer extending over the entire widthwise extent of the sheet, embedding grit in said coating, applying a second continuous layer of bituminous coating in the form of a central longitudinal band narrower than the sheet, embedding grit in said second layer of coating, slitting the sheet longitudinally along its median line, and severing shingle elements from the strips formed by said slitting. Q

4. In the manufacture of' asphalt roofing elements, a process which comprises applying a continuous layer of bituminous coating to a face of a sheet of waterproof fibrous m aterial, said layer extending over the entire widthwise extent of the sheet, embedding grit in said layer, applying a plurality of additional superposed layers of bituminous coating in successively narrower bands, each of said bands having its median line coincident with the median line of the sheet, embedding grit in each said layer before applying the next layer, slitting the sheet along its media-n line, and severing individual elements from the strips formed by the slitting.

5. In the manufacture of asphalt roofing elements, a process which comprises applying to an elongated sheet of rooting felt a plurality of superposed bands of asphalt, one of said bands being wider than another of said bands, all said bands having their median line approximately coinciding with that ofthe sheet, slitting the coated sheet along its median line, and cutting the sections thus` formed into individual rooting units.

6. In the manufacture of asphalt roofing elements, a process which comprises applying to an elongated sheet of roofing felt a plurality of superposed bands of asphalt of different widths, each band having its median line approximately coinciding with that of the sheet, partially embedding a layer of grit in each band while the asphalt thereon is sticky, slit-ting the coated sheet along its median line, and cutting the sections thus formed into individual roofing units.

7 In the manufacture of asphalt rooting elements, a process which comprises applying to an elongated sheet of rooting felt a plurality of superposed bands of asphalt, partially embedding a layer of grit in at least one of said 'bands while the asphalt thereon is sticky, one of said bands being wider than another of said bands, all of said bands having their median lines approximately coinciding with that of the sheet, slitting the coated sheet along its median line, and cutting the sections thus formed into individual units.

In testimony whereof we have affixed our signatures.

LESTER KIRSCHBRAUN. OTTO A. HEPPES. 

